Related Manuals for Sera M 409.2 Series
Summary of Contents for Sera M 409.2 Series
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Page 2: Table Of Contents
4.7.11 Diaphragm rupture monitoring device (option) ................. 22 5. Technical Data ............................24 5.1 Output data ............................24 5.2 Motor data ............................25 5.3 Dimensions ............................26 6. Assembly / Installation ..........................32 TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! - Page 3 13. Fault analysis and corrective action ....................66 14. Shut-down .............................. 68 15. Disposal ..............................68 15.1 Dismantling and transport ........................ 68 15.2 Complete disposal ..........................68 16. Clearance Certificate ..........................69 TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
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Page 4: General
1. General 1.1 General user information Before commissioning and during operation of the sera dosing pump the respective regulations valid at the place of installation are to be observed. The sera dosing pump is delivered ready for installation. Carefully read these instructions and especially the safety instructions herein contained before installation and initial start-up of the pump. -
Page 5: Quality Instructions
■ reduce repair cost and downtime. ■ The sera quality management and quality assurance system for pumps, systems, valves and fittings and compressors is certified according to ISO 9001:2008. The sera product meets the valid safety and accident prevention regulations. -
Page 6: Safety Instructions For Owner / Operator
Chapter 2.8 of these operating instructions. 2.8 Intended use The sera product is only to be deployed according to the intended purpose stated in the product description and the acceptance test certificate. If the product is to be used for other applications, then the suitability of the product for the new operating conditions... -
Page 7: Operating Conditions
NOTE! NOTE! 2.11 Utilities/Lubricants If not agreed otherwise in the contract conditions, the sera dosing pump will always be supplied with the necessary utilities. (For type and quantitiy of utilities/lubricants, see Chapter 11.1 „Working materials“). TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com... -
Page 8: Foreseeable Misuse
Diaphragm rupture is not indicated when the MBE plug was disconnected. Medium can escape into the envi- ■ ronment through the vent hole “Danger to the operator and the environment”. TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! -
Page 9: Maintenance/Repair
■ the assembly pump, electronics opened). Prescribed maintenance schedules ignored. ■ Use of wrong spare parts/oils (e.g. no sera original spare parts, wrong viscosity). ■ Improper mounting of spare and wearing parts (e.g. wrong tightening torque for pump body). ■... -
Page 10: Disassembly
3. Transport and storage 3.1 General sera products are checked for perfect condition and function previous to shipment. Check for transport damage immediately after arrival of goods. If damage is found, this is to be reported immediately to the responsible carrier and the manufacturer. -
Page 11: Transport
If these values are exceeded, metal products should be sealed in foil and protected from condensation water with a suitable desiccant. Do not store solvents, fuels, lubricants, chemicals, acids, disinfectants and similar in the storage room. TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com... -
Page 12: Product Description
(motor driven pumps) (motor driven pumps) Revision index max. Nominal capacity (litre/hour (each pump head)) Displacer (type of construction) Double diaphragm (without) Single diap hragm Multy-layer diaphragm Piston Diaphragm Piston (example) TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! -
Page 13: Type Plate
Diaphragm pump 409.2 Operating Instructions 4.1.2 Type plate Each sera dosing pump is factory provided with a type plate. The following information can be found on this type plate. Type min/max 1/min Hydrfl Designation Pump type Serial number of the pump Minimum/maximum permissible pressure in the pump inlet Minimum/maximum permissible pressure in the inlet cross section which the pump can be used for. -
Page 14: Components Of The Diaphragm Pump
Diaphragm pump 409.2 Operating Instructions 4.6 Components of the diaphragm pump TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! - Page 15 Pump body (standard design) Pump body with integrated overflow valve Stroke frequency transmitter (with inductive contact) option Actuator for Ex-area option EExeIIT4 - motor option illustrated Pneumatic actuator option TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
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Page 16: Functional Description
4.7 Functional description 4.7.1 General sera dosing pumps are run-dry safe oscillating displacement pumps that are characterised by high tightness of the dosing head. The fluid is conveyed by a deformable diaphragm. Dosing pumps consist of the following (main) components: Drive motor ■... - Page 17 (connecting rod does no longer hit the adjusting spindle (4)). Insert percent scale again. ■ Use the setscrew to secure the percent scale to the ■ hand wheel. Adjust desired stroke length. ■ TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
- Page 18 Activation is performed by appropriate control units (see sera - accessories) The set stroke length can be read off on the pump (percent scale) Information on the electrical connection is given inside the cover of the actuator.
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Page 19: Assembly Pump
When the pressure in the pump body falls below the pressure set the diaphragm closes the inlet channel again. TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com... -
Page 20: Manual Vent Valve (Only Frp-Execution
Open vent screw with great caution and perform max. 1 turn. Take care that the tightness of the thread is still guaranteed. ATTENTION! The vent screw must always be closed during the driving process. ATTENTION! TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! -
Page 21: Suction / Pressure Valve
ATTENTION! 4.7.10 Stroke frequency transmitter (option) sera dosing pumps are oscillating displacement pumps with an exactly defined stroke volume per each pump stroke. If these dosing pumps should be used for automatic filling pro- cesses or charge dosing, then the single pump strokes must be determined and converted into electrical signals. -
Page 22: Diaphragm Rupture Monitoring Device (Option)
The pumped medium must have a minimum conductivity of at least 5 µS/cm! ATTENTION! An electrode together with an approprate evaluation unit (option, e.g. sera diaphragm rupture relay, type ER-104 (or ER-142 for Ex-areas respectively) is used for monitoring. The diaphragm rupture electrode is mounted directly to the pump, the evaluation unit inside the switch cabinet. - Page 23 (please see Fig. in Chap. „Components of the diaphragm pump“) NOTE! sera - dosing pumps can be retrofitted with a dia-phragm rupture electrode. NOTE! Maintenance of the diaphragm rupture electrodes is limited to cleaning (e.g. during an exchange, please see chapter „Changing the Diaphragm“.
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Page 24: Technical Data
Linear dosing range at a stroke length between 30% and 100%. Standard design. The nominal data refer to water, 20°C and nominal pressure. With lower counterpressure it can come to be soaked off achievements. TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! -
Page 25: Motor Data
II2G EExe IIT4 EExdeIIT4-motor (pressure-tight enclo- 0,37 1.500 II2G EExde IICT4 sed) The data can be read off the type plate on the drive motor of the respective diaphragm pump! TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com... -
Page 26: Dimensions
Diaphragm pump 409.2 Operating Instructions 5.3 Dimensions 147,5 (BG63) M (1-4) 154,5 (BG71) 47,5 □ Mounting holes for removing the actuar cover Manual vent valve (...409.2-0,8e - 2,4e, FRP-design) TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! - Page 27 Diaphragm rupture signalling MBE-02 Stroke frequency transmitter Stroke a.o. Dimensions for fastening of see dimensional drawing mechanism the pump DN 8 for double valves 1.4571/1.4581 DN 5 for single valves PVC TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
- Page 28 Angle, socket overflow valve Diaphragm rupture signalling MBE-02 Stroke frequency transmitter Stroke a.o. Dimensions for fastening of see dimensional drawing mechanism the pump Connection thread G1 for single valves DN15 TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications!
- Page 29 Angle MBE-03/04 Stroke frequency transmitter Stroke a.o. Dimensions for fastening of see dimensional drawing mechanism the pump DN 8 for double valves 1.4571/1.4581 DN 5 for single valves PVC TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
- Page 30 25° 25° 70° 70° Angle MBE 03/04 Stroke frequency transmitter Stroke a.o. Dimensions for fastening of see dimensional drawing mechanism the pump Connection thread G1 for single valves DN15 TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications!
- Page 31 Manual SLA with position indicator Electric actuator Electric actuator with PMR3 Electric actuator, Ex-design Pneumatic actuator Standard motor Motor for frequency con- verter operation AC motor EExeIIT4 - motor TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
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Page 32: Assembly / Installation
Use pressure- and medium-resistant hoses / pipes. ■ All pipes and containers connected to the pump must comply with the regulations and must be cleaned, tension-free ■ and intact. TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! - Page 33 Flushing medium Check valve Safety valve Vent valve (ball valve) Diaphragm relief valve Injection fitting Pressure keeping valve Shut-off valve Dosing pump with integrated relief valve Strainer Dosing pump CS... TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
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Page 34: Provide For An Overpressure Protection
If the permissible pressure in the system may be exceeded, e.g. when a shut-off valve is closed or if the line is blocked: Install the overflow valve (19). ■ Use sera - diaphragm pump with integrated overflow valve. ■ When using an external relief valve the following is valid for the feed back pipe: Lead the overflow line with descending gradient in the store tank which is under atmospheric pressure or in an ■... -
Page 35: Preventing A Backflow Of The Pumped Medium
DANGER! Pay attention to / avoid chemical reactions arising from a backflow of the pumped medium. DANGER! TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com... -
Page 36: Eliminating Undesired Siphoning
Install a vent valve (8) into the pressure line ■ The delivery may be interrupted if air enter in the suction line! NOTE! TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! -
Page 37: Install The Empty-Tank Alarm
TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com... -
Page 38: Line Strainer
For use with high tanks without connection on the tank bottom: Install the siphon vessel ■ Pay attention to accelerating pressure which may be genera- ■ ted in a long suction line. TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! -
Page 39: In Case Of Easily Degassing Pumped Media
■ rinsing when pump was switched off. ■ Rinsing is absolutely required after the dosing pump was switched off! ATTENTION! The rinsing process should be automated. NOTE! TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com... -
Page 40: Damping Of The Pulsation
Installation of suction and/or pressure pulsation dampers near the pump head. If both pulsation damper and pressure keeping valve (20) should be integrated install the pressure keeping valve ■ between pump and pulsation damper. TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! - Page 41 Mechanical breakdown of the pump, leakage and valve wobbles as a result of the ■ maximum pressure on the pressure side of the pump being exceeded. Damage to the pipe and in the pipe installed fittings. ■ TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
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Page 42: Electrical Connection / Interfaces
Diaphragm pump 409.2 Operating Instructions 7. Electrical connection / Interfaces sera diaphragm pumps are driven either by a three-phase motor or an AC motor. 7.1 Motor connection In case of a three-phase motor The motor connection depends on the voltage indication on the type plate and the applied supply voltage. -
Page 43: Operation In Explosion-Hazardous Areas
DANGER! The product supplied by sera meets the requirements of directive 2014/34/EU if it is correspondingly marked. This gua- rantees safe operation in explosion-hazardous areas. It is the operator’s task to define the field of application and to check whether the pump is suited for this application. -
Page 44: Operation
The maintenance notes listed in Chapter 10 are generally applicable. Exception: The oil level in the stroke mechanism of the pump and the level of the hydraulic fluid of the pump must be checked once a week! CAUTION! TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! -
Page 45: Start-Up
(see table Chap. „Overview of the tightening torques“). Check whether all electrical connections are correct. ■ Check whether the information of the mains voltage on the type plate with the local circumstances agrees. ■ TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com... -
Page 46: Operation
The flow capacity of the dosing pump is set via the stroke length control (see chapter „Stroke length adjustment“). When using an electrical actuator or frequency converter please take note of the separate operating instructions! NOTE! TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! -
Page 47: Maintenance
The following safety instructions apply to all service and are sure to follow. Carry out all maintenance work only on non-pressurized system! WARNING! Repairs on the stroke mechanism may only be performed by sera! WARNING! Before starting maintenance make sure that the wearing parts and the spare parts required are available. -
Page 48: Working Materials
Diaphragm pump 409.2 Operating Instructions 11.1 Working materials Pump type Specification sera use Quantity ARAL CLP VG220 Degol ...409.2-... DIN51517-3 0,3 Litres BG220 Quantity Pump type Type intermediate diaphragm PTFE PTFE-laminated ...409.2-4,0 6,5 cm 6,5 cm 7,5 cm ...409.2-4,0 with MBE-03... -
Page 49: Drive Unit
Fill oil in threaded hole of the venting screw. ■ For type and quantitiy of the gear oil, please see ■ Chapter “Working materials“. Screw in venting screw (5). ■ TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com... -
Page 50: Dosing Unit
...409.2-2,4 e ...409.2-4,0 (e) ...409.2-7,0 (e) ...409.2-12 (e) ...409.2-18 (e) ...409.2-25 (e) ...409.2-50 (e) ...409.2-75 (e) ...409.2-90 (e) ...409.2-115 (e) ...409.2-140 (e) ...409.2-180 (e) ...409.2-250 (e) 15,0 15,0 ...409.2-350 (e) TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! -
Page 51: Changing The Diaphragm
When assembling the pump body, please note:suction ■ valve below, pressure valve above! Add the suction and pressure line and connect pump to the power supply. The diaphragm pump is then again ready for operation. TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com... - Page 52 (8) is to be filled in with a disposable syrin- ge (12). Venting the buffer fluid chamber: ■ wait for appr. 2 minutes after filling in until the air dis- solved in the buffer fluid has outgassed. TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications!
- Page 53 Proceed as follows to change the diaphragm of the overflow valve (only dosing pumps with integrated overflow valve). All diaphragms should be replaced completely. NOTE! Loosen and unscrew the lid (1) of the overflow valve. TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
- Page 54 Check overflow valve for damage and contamination. ■ Insert a new diaphragm. In case of PTFE-laminated diaphragms the PTFE-coated side must point to- ■ wards the pump body. Assemble the pump in reversed order. ■ TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications!
- Page 55 “T”! The screw-in depth of the set screw must not exceed the initial value. If the set pressure is increased, sera has to be consulted beforehand! ATTENTION! Never screw in the set screw to a depth so that the pres-sure spring is com-...
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Page 56: Spare And Wearing Parts
Chapter “Diaphragm rupture monitoring device “ (Functional description)). 12.2 Spare parts The following parts are considered as spare parts of the diaphragm pump: Pump body ■ Diaphragm ring (only for double diaphragm pump) ■ TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! -
Page 57: Spare And Wearing Parts
Pump body Pos. consisting of Pump body kit (plastic) Pressure valve (incl. o-rings) Pos. consisting of Diaphragm kit Screws, complete Pos. consisting of Front plate Drive diaphragm Pump body TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com... -
Page 58: Diaphragm Pump
...409.2 - 18 (e) ...409.2 - 25 (e) ...409.2 - 50 (e) ...409.2 - 75 (e) ...409.2 - 90 (e) ...409.2 - 115 (e) ...409.2 - 140 (e) ...409.2 - 180 (e) TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! - Page 59 Intermediate diaphragm Pump body Drive diaphragm Pressure plate (not with a laminated drive diaphragm) Buffer fluid Diaphragm ring kit (only for double diaphragm pump) Pos. consisting of Diaphragm ring, complete TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
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Page 60: Diaphragm Pump
Diaphragm pump 409.2 Operating Instructions 12.3.3 Diaphragm pump ...409.2-250 (e) ...-350 (e) ...409.2 - 250 (e) ...409.2 - 350 (e) TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! - Page 61 Drive diaphragm Diaphragm kit (double diaphragm pump) Pos. consisting of Intermediate diaphragm Drive diaphragm Buffer fluid Diaphragm ring kit (only for double diaphragm pump) Pos. consisting of Diaphragm ring, complete TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
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Page 62: With Integrated Overflow Valve
...409.2 - 18 (e) ...409.2 - 25 (e) ...409.2 - 50 (e) ...409.2 - 75 (e) ...409.2 - 90 (e) ...409.2 - 115 (e) ...409.2 - 140 (e) ...409.2 - 180 (e) TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! - Page 63 Pressure plate Socket (not with a laminated drive diaphragm) O-ring Diaphragm (overflow valve) Buffer fluid Diaphragm ring kit (only for double diaphragm pump) Pos. consisting of Diaphragm ring, complete TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
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Page 64: Diaphragm Pump
Diaphragm pump 409.2 Operating Instructions 12.3.5 Diaphragm pump ...409.2-250 (e) ...-350 (e) with integrated overflow valve ...409.2 - 250 (e) ...409.2 - 350 (e) TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! - Page 65 Pump body kit (special steel) Pos. consisting of Diaphragm ring kit (only for double diaphragm pump) Screws, complete Pos. consisting of Pump body Diaphragm ring, complete O-ring Socket O-ring TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
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Page 66: Fault Analysis And Corrective Action
13. Fault analysis and corrective action sera - products are proven technical products which are only shipped after an extensive final test in our works. Should any malfunctions occur, these can be located and corrected easily with the help of the following reference guide . - Page 67 Medium frozen in pipe. and check for damages raise temperature. Replace the diaphragm according █ █ █ █ █ █ █ Diaphragm rupture. to the descriptions in Chapter „Replacing the diaphragm“. TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
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Page 68: Shut-Down
Drain off lubricants and dispose of according to regulations! ■ Dismount materials and send them to a suitable waste disposal company! ■ The consignor is responsible for leaking lubricants or fluids! WARNING! TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications! -
Page 69: Clearance Certificate
The clearance certificate is part of the inspection-/repair order. sera reserves the right to refuse acceptance of the order for other reasons. Please make a copy and leave the original with the operating instructions! (can also be downloaded from: www.sera-web.com) - Page 70 Certificate) have been correctly and completely and that the returned parts were carefully cleaned. The parts are sent free of residues of dangerous amount. Place, Date Department Signature (and company stamp) www.sera-web.com TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications!
- Page 71 Diaphragm pump 409.2 Operating Instructions NOTE TA 410 Rev. 16 en 10/2016 Subject to technical modifications! www.sera-web.com...
- Page 72 TA 410 Rev. 16 en 10/2016 www.sera-web.com Subject to technical modifications!
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